CN111443516A - Optical composite film and preparation method thereof - Google Patents

Optical composite film and preparation method thereof Download PDF

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Publication number
CN111443516A
CN111443516A CN201910912348.0A CN201910912348A CN111443516A CN 111443516 A CN111443516 A CN 111443516A CN 201910912348 A CN201910912348 A CN 201910912348A CN 111443516 A CN111443516 A CN 111443516A
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layer
optical
film
optical film
substrate
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Inventor
李刚
余洋
张毅
于振江
陈�胜
叶群
朱建辉
顾春红
张彦
唐海江
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Ningbo Exciton Technology Co Ltd
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Ningbo Exciton Technology Co Ltd
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Priority to CN201910912348.0A priority Critical patent/CN111443516A/en
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    • G—PHYSICS
    • G02—OPTICS
    • G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
    • G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells
    • G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
    • G02F1/1333—Constructional arrangements; Manufacturing methods
    • G02F1/1335—Structural association of cells with optical devices, e.g. polarisers or reflectors
    • G02F1/133504—Diffusing, scattering, diffracting elements
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/02—Diffusing elements; Afocal elements
    • G02B5/0205—Diffusing elements; Afocal elements characterised by the diffusing properties
    • G02B5/0236—Diffusing elements; Afocal elements characterised by the diffusing properties the diffusion taking place within the volume of the element
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/02—Diffusing elements; Afocal elements
    • G02B5/0205—Diffusing elements; Afocal elements characterised by the diffusing properties
    • G02B5/0236—Diffusing elements; Afocal elements characterised by the diffusing properties the diffusion taking place within the volume of the element
    • G02B5/0242—Diffusing elements; Afocal elements characterised by the diffusing properties the diffusion taking place within the volume of the element by means of dispersed particles
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/02—Diffusing elements; Afocal elements
    • G02B5/0268—Diffusing elements; Afocal elements characterized by the fabrication or manufacturing method
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/02—Diffusing elements; Afocal elements
    • G02B5/0273—Diffusing elements; Afocal elements characterized by the use
    • G02B5/0278—Diffusing elements; Afocal elements characterized by the use used in transmission
    • G—PHYSICS
    • G02—OPTICS
    • G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
    • G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells
    • G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
    • G02F1/1333—Constructional arrangements; Manufacturing methods
    • G02F1/1335—Structural association of cells with optical devices, e.g. polarisers or reflectors
    • G02F1/1336—Illuminating devices
    • G02F1/133602—Direct backlight
    • G02F1/133606—Direct backlight including a specially adapted diffusing, scattering or light controlling members
    • G—PHYSICS
    • G02—OPTICS
    • G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
    • G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells
    • G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
    • G02F1/1333—Constructional arrangements; Manufacturing methods
    • G02F1/1335—Structural association of cells with optical devices, e.g. polarisers or reflectors
    • G02F1/133504—Diffusing, scattering, diffracting elements
    • G02F1/133507—Films for enhancing the luminance
    • G—PHYSICS
    • G02—OPTICS
    • G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
    • G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells
    • G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
    • G02F1/1333—Constructional arrangements; Manufacturing methods
    • G02F1/1335—Structural association of cells with optical devices, e.g. polarisers or reflectors
    • G02F1/1336—Illuminating devices
    • G02F1/133602—Direct backlight
    • G02F1/133606—Direct backlight including a specially adapted diffusing, scattering or light controlling members
    • G02F1/133607—Direct backlight including a specially adapted diffusing, scattering or light controlling members the light controlling member including light directing or refracting elements, e.g. prisms or lenses

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  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Nonlinear Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Mathematical Physics (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Dispersion Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Optical Elements Other Than Lenses (AREA)

Abstract

The invention relates to the field of optical films for backlight modules, in particular to an optical composite film and a preparation method thereof. The invention provides an optical composite film and a preparation method thereof, aiming at solving the problem that the existing composite film can not give consideration to luminance gain, covering property and interference elimination. The optical composite film includes: a first layer of optical film and a second layer of optical film; the first layer of optical film is arranged above the second layer of optical film, and the first layer of optical film and the second layer of optical film are bonded together through the laminating layer; the first optical film layer sequentially comprises a micro-lens structure layer and a first substrate layer; the second layer of optical film comprises a prism layer, a second substrate layer and a back coating layer in sequence. The optical composite film provided by the invention can improve the luminance gain effect, has a good covering effect, and has excellent interference resolution performance. The production cost of the micro-lens structure is greatly reduced by utilizing the preparation method of the micro-lens film provided by the invention.

Description

Optical composite film and preparation method thereof
Technical Field
The invention relates to the field of optical films for backlight modules, in particular to an optical composite film and a preparation method thereof.
Background
The optical film with brightness enhancement and diffusion functions in the backlight module generally comprises a brightness enhancement film, a micro-lens film and a diffusion film. With the recent trend of liquid crystal display towards 'large size', 'thin and light', the demand for high performance optical films will increase greatly, and under the current trend of ultra-thin optical displays, how to design suitable products to further thin the backlight module is a subject of consideration in various component manufacturers. Therefore, the optical composite of brightness enhancement film, microlens film, diffusion film, etc. is a new research focus because it can adapt to the current trend of ultra-thin and large size.
The optical composite film as a new optical film upgrading variety has become another new optical film manufacturing high point by virtue of higher assembly yield, lower comprehensive cost, good anti-warping effect and more thinning space.
Brightness enhancing films, which are often used as a material choice for one or more layers of a composite film due to their higher brightness, can enhance the brightness of liquid crystal displays by optically collecting light within an effective viewing angle range, primarily by microreplicating a layer of microprismatic structures on a substrate, but are structurally regular, particularly with the prismatic structures as the uppermost layer, which tend to interfere. The micro lens film has the functions of an optical brightness enhancement film and an optical diffusion film and is used for enhancing the brightness of a light emitting surface and widening an optical visual angle, so that the micro lens film can improve the optical gain of the liquid crystal display, has a certain atomization effect of scattered light rays, can improve the covering property, and is often used for being designed as an upper layer material of a composite film; however, most of the conventional microlens films have regular lens structures, and have a serious interference problem. The diffusion film has a random arrangement of diffusion structures formed by coating particles of different sizes on the surface of a substrate, and thus has high hiding properties and light scattering properties, and is less likely to cause interference when used as an upper layer of a composite film, but has low brightness. In addition, the above products suffer from one or more of the following disadvantages: (1) the micro-lens film is generally carved into a regular micro-lens structure with the same size, and interference is easy to generate; (2) the diffusion surface of the diffusion film is generally composed of glue and particles, and multiple refraction and scattering brightness reduction are generated due to the difference of refractive indexes; (3) the diffusion film has more particles, so that the problems of particle falling and the like are easily caused in the cutting, transporting and assembling processes.
In particular to a production method of a micro-lens film, which is generally formed by coating photo-curing glue on a processed micro-structure metal mold on UV photo-curing coating equipment. At present, the conventional method is to use a laser engraving process to engrave different types of micro-lens structures on a metal roller; the preparation method of the diffusion film generally comprises the steps of coating glue particles on a base material, and forming a diffusion structure through heat/ultraviolet curing;
the above engravings have several problems: 1) the engraving cost is extremely high, the preparation of a single roller can reach hundreds of thousands of processing expenses, and the unit price cost of the existing optical film is seriously exceeded; 2) microlenses that replace optical diffuser films or brightness enhancement films are typically high brightness, high haze, generally small diameter (<30 μm) microlenses, low yield of engraving, long time periods; 3) the engraving difficulty is relatively high, the engraving process is complex, the yield is low, and the production cost of the product can be greatly increased.
The above method of coating a diffusion structure has several problems: 1) the coating diffusion particles generally have solvents, so that the environment is polluted, the curing time is long, and the energy consumption is large; 2) the formula of the diffusion glue and the solvent is complex, and the problems of uneven coating, incomplete curing and the like easily occur in production; 3) in the coating process, the diffusion particles are wrapped in the glue solution, the refractive index difference is large, multiple refractions can be generated, and the brightness is influenced.
Disclosure of Invention
The invention provides an optical composite film and a preparation method thereof, aiming at solving the problem that the existing composite film can not give consideration to luminance gain, covering property and interference elimination. The optical composite film provided by the invention can improve the luminance gain effect, has a good covering effect, and has excellent interference resolution performance. The production cost of the micro-lens structure is greatly reduced by utilizing the preparation method of the micro-lens film provided by the invention. The preparation method of the optical composite film greatly reduces the manufacturing cost of the upper-layer micro-lens structure, has simple preparation process, is suitable for batch production, omits the working procedures of carving and die turnover, and greatly reduces the working difficulty and the preparation cost.
In order to achieve the above purpose, the invention provides the following technical scheme.
The present invention provides an optical composite film comprising: a first optical film (first optical film for short) and a second optical film (second optical film for short); the first layer of optical film is arranged above the second layer of optical film, and the first layer of optical film and the second layer of optical film are bonded together through the laminating layer; the first optical film layer sequentially comprises a micro-lens structure layer and a first substrate layer from top to bottom; the second layer of optical film sequentially comprises a prism layer, a second base material layer and a back coating layer from top to bottom.
The first optical film layer sequentially consists of a micro-lens structure layer and a first substrate layer from top to bottom; the second layer of optical film sequentially consists of a prism layer, a second base material layer and a back coating layer from top to bottom.
The optical composite film sequentially comprises the micro-lens structure layer, the first substrate layer, the laminating layer, the prism layer, the second substrate layer and the back coating layer from top to bottom.
The first substrate layer of the first optical film is bonded with the prism layer of the second optical film through the laminating layer.
Furthermore, the first layer of optical film is a micro-lens film and comprises a substrate layer and a micro-lens structure layer above the substrate layer.
Further, the second layer of optical film is a brightness enhancement film and comprises a substrate layer, a prism layer above the substrate layer and a back coating below the substrate.
The laminating layer is adhesive.
Furthermore, the composite film enters light from the lower layer (back coating) of the second layer of optical film and emits light from the upper layer (micro-lens structure layer) of the first layer of optical film.
Further, the micro-lens structure layer comprises a micro-lens structure (micro-lens for short) and a glue layer, the micro-lens structure is bonded on the upper surface of the first substrate layer through the glue layer, and the micro-lens structure and the glue layer are made of the same material.
Further, in the preparation process, the micro-lens structure and the glue layer are integrally formed.
Furthermore, the material of the micro-lens structure layer is the same as that of the substrate layer.
Further, the micro-lens structure of the first layer of optical film is selected from arc-shaped bulges.
Further, the arc-shaped protrusions are different in size.
The microlens structure layer of the first optical film includes randomly arranged arc-shaped convex structures (also called convex spherical structures) with different sizes.
The arc-shaped convex structure plays a role in diffusing light. The arc-shaped convex structure is the micro lens.
In the arc-shaped protrusion structure, the contour line of the cross section passing through the highest point of the protrusion is an arc line. The arc-shaped protrusion can be a semi-ellipsoid, a hemisphere, a segment or a similar structure, and can also be a shape formed by extending the semi-ellipsoid, the hemisphere or the segment in height.
Further, the curved convex structures (also referred to as spherical convex structures) are selected from convex semi-ellipsoids, hemispheres, segments or similar structures.
The width of the arc-shaped protruding structure is the maximum width of the section where the arc-shaped protrusion is connected with the base material layer, and the height of the arc-shaped protruding structure is the distance between the highest point of the arc-shaped protrusion and the wave trough of the arc-shaped protrusion. If the arc-shaped convex structure is a hemisphere, the width of the arc-shaped convex structure is the diameter of the hemisphere, the height of the arc-shaped convex structure is the radius of the hemisphere, and the aspect ratio of the arc-shaped convex structure is 0.5.
Further, the micro-lens structure comprises arc-shaped bulges with different widths. Alternatively, the arc-shaped protrusions are composed of arc-shaped protrusions having different widths.
Furthermore, the width of the arc-shaped bulge is 10-100 μm, and the aspect ratio is 0.3-0.6.
Further, the arcuate projections are selected from hemispheres, and/or segments. The length P of the bottom edge of the segment is 10-100 μm, the height-to-width ratio is the ratio of the height H/P of the segment, and the height-to-width ratio is 0.3-0.6.
Furthermore, the width of the arc-shaped bulge is 20-60 mu m, and the aspect ratio is 0.35-0.55.
Furthermore, the width of the arc-shaped bulge is 25-45 μm, and the aspect ratio is 0.4-0.5.
Furthermore, the width of the arc-shaped protrusions can be in uniform size distribution or in mixed distribution with different sizes.
Further, when the sizes are uniformly distributed, the width can be selected to be any 1 size specification of 25-45 um.
Furthermore, when the segment structures are mixed and distributed, the segment structures are matched and combined with two types of large balls and small balls, the diameter of each large ball is 40-45um, and the diameter of each small ball is 25-30 um.
Further, the arc-shaped bulge comprises a large bulge and a small bulge, the diameter of the large bulge is 40-45um, and the diameter of the small bulge is 25-30 um. Further, the number ratio of the large protrusions to the small protrusions is 1:10-1: 1.
Furthermore, the number ratio of the big balls to the small balls is 1:10-1: 1.
Further, the duty ratio of the arc-shaped bulge (convex spherical structure) is more than or equal to 60%. The duty cycle is 60% -95%. The duty cycle is the percentage of the area of the bottom surface of the arcuate projections on one surface of the substrate layer of the first optical film.
Further, the first optical film substrate may be selected from polyethylene terephthalate (PET), Polycarbonate (PC), polyvinyl chloride (PVC), or Polymethylmethacrylate (PMMA), and the thickness thereof may be selected from 38 μm to 250 μm.
The liquid refractive index of the arc-shaped protrusion (convex spherical structure) resin is selected from 1.44-1.60. Further, the liquid refractive index of the resin is selected from 1.46 to 1.56. Further, the refractive index of the resin is selected from 1.48 to 1.52.
The second layer of optical film is a microprism film, and the upper surface of the microprism film is of a strip-shaped microprism structure.
Furthermore, the distance between the micro prism structures is 20-90 μm, and the prism structures can be of equal height structures and can also be matched with high and low structures. The prism angle is 90 degrees. The apex angle of the prism includes a rounded corner, a sharp corner, and a flat shape. The micro prism structure is a prism column (or prism strip) with a triangular cross section.
Further, the resin of the prism structure is selected from UV curing resin, and the refractive index is selected from 1.53-1.58.
Furthermore, the hardness of the prism structure after the first section is solidified needs to be less than H, and a semi-solidified state is kept. The first stage of curing refers to UV pre-curing, which is intended to keep the prism structure demoulded, and post-curing is performed during the application, after which the prism structure is cured completely.
The substrate of the second optical film may be selected from polyethylene terephthalate (PET), Polycarbonate (PC), polyvinyl chloride (PVC), or Polymethylmethacrylate (PMMA), and the thickness thereof may be selected from 38 μm to 250 μm.
The lower layer of the second optical film is a back coating, and the haze of the second optical film can be between 3 and 20 percent.
The adhesive of the laminating layer is selected from UV-cured acrylate type, and the thickness of the laminating layer is controlled to be 0.5-5 mu m.
Further, in the first optical film, the microlenses in the microlens structure layer are hemispherical, the width (diameter) of the hemispherical microlenses is 10-100 μm, the aspect ratio is 0.3-0.6, the duty ratio is 60-95%, the refractive index of the liquid resin adopted by the microlenses is 1.44-1.60, the material of the first substrate layer is selected from one of polyethylene terephthalate (PET), Polycarbonate (PC), polyvinyl chloride (PVC) or polymethyl methacrylate (PMMA), and the thickness of the first substrate layer is 38-250 μm; in the second layer of optical film, the distance between the strip-shaped prism structures of the prism layer is 20-90 μm, the liquid refractive index of the resin adopted by the prism structures is 1.53-1.58, the material of the second layer of substrate layer is selected from one of polyethylene terephthalate (PET), Polycarbonate (PC), polyvinyl chloride (PVC) or polymethyl methacrylate (PMMA), and the thickness of the second layer of substrate layer is 38-250 μm; the thickness of the attaching layer is 0.5-5 μm.
Further, in the first optical film, the microlenses in the microlens structure layer are hemispherical, the width (diameter) of the hemispherical microlenses is 20-60 μm, the aspect ratio is 0.35-0.55, the duty ratio is 70-95%, the refractive index of the liquid resin adopted by the microlenses is 1.46-1.56, the material of the first substrate layer is selected from polyethylene terephthalate (PET) or Polycarbonate (PC), and the thickness of the first substrate layer is 100-188 μm; in the second layer optical film, the distance between the strip-shaped prism structures of the prism layer is 30-80 μm, the refractive index of the resin adopted by the prism structures is 1.54-1.57, the material of the second layer substrate layer is selected from polyethylene terephthalate (PET) or Polycarbonate (PC), and the thickness of the second layer substrate layer is 100-188 μm; the thickness of the attaching layer is 0.5-2 μm. The foregoing technical solutions include examples 5 to 10.
Further, in the first optical film, the microlenses in the microlens structure layer are hemispherical, the width (diameter) of the hemispherical microlenses is 25-45 μm, the aspect ratio is 0.4-0.5, the duty ratio is 85-95%, the refractive index of the liquid resin adopted by the microlenses is 1.48-1.52, the material of the first substrate layer is selected from polyethylene terephthalate (PET), and the thickness of the first substrate layer is 125 μm; in the second layer optical film, the distance between the strip-shaped prism structures of the prism layer is 60-70 μm, the refractive index of resin adopted by the prism structures is 1.55-1.56, the material of the second layer substrate layer is selected from polyethylene terephthalate (PET), and the thickness of the second layer substrate layer is 125 μm; the thickness of the attaching layer is 0.5-1.2 μm. The foregoing technical solutions include examples 8 to 10.
The invention also provides a preparation method of the optical composite film, which comprises the following steps:
1. preparation of the first layer optical film
(1) Preparing a microstructure substrate: distributing a layer of micro-particles on the surface of a substrate by an autodeposition method, and then depositing glue in the gaps among the particles in a deposition mode;
(2) removing the microstructure particles, and preparing a master plate: coating polymer resin on the microparticle layer on the upper surface of the substrate prepared with the glue deposition layer and the microparticle layer, and curing the polymer resin to form close adhesion with the microparticles; peeling the uppermost layer of polymer resin and the microparticles from the substrate, and leaving the substrate and the glue deposition layer, wherein the upper surface of the glue deposition layer forms a concave microstructure arrangement layer, and the part is the prepared mother film;
(3) preparation of microlens film: the mother film is coated on the outer wall of the production line roller, the seam is bonded through an adhesive tape, glue is coated on the surface of the first layer of the base material layer, a glue layer is pressed on the surface of the mother film with the concave microstructures, the glue is solidified, and the convex microstructure lens layer can be formed on the first optical surface of the first layer of the base material layer, so that the first layer of the optical film can be obtained.
Further, the preparation method also comprises the following steps:
2. preparing a lower back coating of the second optical film layer;
3. and preparing a microprism structure layer on the second optical film, coating adhesive on the lower surface of the first optical film, and bonding the lower surface of the first optical film and the microprism structure on the upper surface of the second optical film through the adhesive. Thus obtaining the optical composite film of the invention.
Further, the preparation method of the optical composite film provided by the invention comprises the following steps:
1. preparation of the first layer optical film
The preparation method comprises the following steps:
(1) preparing a microstructure substrate: the method comprises the steps of firstly, uniformly distributing a layer of easily stripped particles with bead structures (micro-particles or particles for short) on the surface of a base material (also called a matrix or a matrix layer) by an autodeposition method, and then, depositing glue with a certain thickness in the gaps among the particles by a deposition method. The deposition thickness of the corresponding glue layer is carried out according to the height-width ratio of the designed segment structure.
Furthermore, a layer of single-layer particles is firstly paved on the base material, and then a layer of glue is independently deposited in the gaps of the particles. And setting the deposition thickness of the glue layer according to the particle size of the bead structure particles and the aspect ratio of the spherical segment.
Further, the bead-structured particles may be polymer particles, such as Polymethylmethacrylate (PMMA), Polybutylmethacrylate (PBMA), Polystyrene (PS), Polyurethane (PU), or Polyamide (PA). And may also be inorganic particles such as silica.
Furthermore, the glue layer can adopt materials such as silicon resin, epoxy resin, fluororesin and the like, and has the release characteristic of easy separation from the selected particle material. And infiltrating the resin solution onto the particles in a deposition mode, and drying the solvent to obtain the microstructure matrix layer with the particles.
(2) Removing the microstructure particles, preparing a master (also called a mother film, or working mother film): the substrate with the deposited layer and the micro-particle layer is coated with polymer resin on the micro-particle layer on the upper surface, and the polymer resin is cured to form close adhesion with the micro-particle. And peeling the uppermost polymer and the particles from the substrate, wherein the rest substrate and the deposition layer form a concave microstructure arrangement layer, and the concave microstructure arrangement layer is the prepared mother film.
The polymer resin is selected from a two-part thermosetting resin composition which is crosslinked with an acrylic polyol, an acrylate, etc. and a polyfunctional isocyanate having good adhesion, or the polymer resin is formed of a two-part thermosetting resin composition of a polyester polyol and a polyisocyanate.
Furthermore, the substrate layer material can be selected from Polycarbonate (PC), polyethylene terephthalate (PET), polymethyl methacrylate (PMMA), etc., and the thickness of the substrate layer material is controlled at 100-300 μm. Furthermore, the length and the width of the working mother film can be cut into corresponding sizes according to the using size of a customer. Further, the length is 1000mm-2000mm, and the width is 680mm-1600 mm.
(3) Preparation of microlens film: the working mother film is coated on the outer wall of a production line roller, a seam is bonded through a special adhesive tape, glue is coated on the surface of the base material, a glue layer is pressed on the surface of the mother film with the concave microstructure and is solidified, and then the convex microstructure lens layer can be formed on the first optical surface of the base material, and the first optical film can be obtained.
Further, the glue is the same as the base material.
2. And preparing a lower back coating of the second optical film.
3. And preparing a microprism structure layer on the second optical film, coating adhesive on the lower surface of the first optical film, and bonding the lower surface of the first optical film and the microprism structure on the upper surface of the second optical film through the adhesive.
The invention has the beneficial effects that: in the traditional diffusion prism composite film, because the particle sizes of the particles of the diffusion layer are different, and the interface refractive index difference exists between the glue and the particles, the brightness cannot be in an optimized state; in addition, the luminance of the finished product is further reduced because the luminance after compounding is relatively lost inevitably by the bonding process. The traditional regular microlens prism composite film is easy to generate poor interference with a panel when in use because microlenses and prisms are in regular structures. The manufacturing method of the micro lens provided by the invention can greatly reduce the production cost of the micro lens structure. According to the micro-lens composite film provided by the invention, the micro-lens layer is designed based on the self structure, the arc-shaped protrusions (such as the spherical segment) come from the concave-convex structure of the micro-lens layer, the micro-lens structure layer and the glue layer are made of the same material, the interface refractive index difference is avoided, and meanwhile, the micro-lens composite film has a high brightness gain effect and a high covering performance. Meanwhile, the arc-shaped bulges are distributed irregularly, so that the interference removing performance is more excellent compared with that of the traditional regular micro-lens.
The preparation method of the micro-lens film greatly reduces the manufacturing cost of the upper micro-lens structure. In the preparation method, the traditional regular microlens convex spherical structure is carved in a carving mode, the carving cost is extremely high, the carving yield is low, the cost is difficult to reduce, and the carving structure lacks the market competitiveness. In the preparation method, the preparation method of the soft film is adopted, the mother film is easy to prepare, the cost is low, the continuous production can be realized, and the preparation cost of the microstructure can be greatly reduced.
The optical composite film provided by the invention has the characteristics of high brightness, high covering property and light interference reduction, and 3-4 traditional films can be replaced by one film, so that the overall optical effect is met, the ultrathin design of the film is realized, the assembly yield is improved, and the cost is greatly reduced.
Drawings
FIG. 1 is a schematic structural view of a conventional diffusing prism composite film;
FIG. 2 is a schematic structural diagram of a conventional regular microlens-prism composite film;
FIG. 3 is a schematic structural diagram of a microlens-prism composite film according to the present invention;
fig. 4 is a schematic view of a process for manufacturing a microlens structure according to the present invention.
Detailed Description
The present invention will be described in further detail with reference to the following specific embodiments and the attached drawings, it should be noted that the embodiments are only used for further illustration of the present invention and should not be construed as limiting the scope of the present invention.
As shown in fig. 3, the optical composite film provided by the present invention includes a first substrate layer 50, a microlens structure layer 51, a laminating layer 52, a second substrate layer 60, a prism layer 61, and a back coating layer 62.
As shown in fig. 4, a schematic flow chart of the preparation of the microlens structure provided by the present invention is shown, wherein 70 is a substrate for self-assembly, and 71 is a deposited bead-structured particle. 72 is glue deposited in the inter-particle spaces. 80 is a resin layer coated on the surface fine particles. 90 is the matrix layer remaining after peeling the upper particles. And 91 is a deposition layer of a concave microstructure which remains after the upper particles are peeled off. 100 is the substrate layer of the finished microstructure. 101 is a micro-structure lens layer composed of arc-shaped bulges.
The composite films provided in the examples of the present invention and the comparative examples were tested for their main properties and comparative parameters in the following manner.
1. Brightness gain test by using a special direct backlight source to test the brightness of L0The optical composite film of the present invention was tested for brightness of L1Then, the luminance gain of the optical composite film of the invention is L1/L0。
2. Covering property: and assembling the cut diaphragm into a direct type backlight module, and observing the covering degree and the diffusion effect of the lamp beads on the display screen at a vertical angle after the backlight module is lightened. Evaluation grade: good > better > bad.
3. Anti-interference: the interference resistance test method is to use a fixed 55-inch TV module, cut and assemble samples with different parameters, and visually observe the appearance contrast interference difference. Evaluation grade: good > better > bad.
The following examples further illustrate the optical composite films and processes provided by the present invention.
Example 1
As shown in fig. 3, the present invention provides an optical composite film comprising: a first layer of optical film and a second layer of optical film; the first layer of optical film is placed over the second layer of optical film, and the two are bonded together by the laminating layer 52; the first optical film layer sequentially comprises a micro-lens structure layer 51 and a first substrate layer 50; the second layer of optical film includes, in order, a prism layer 61, a second substrate layer 60, and a back coat layer 62.
Examples 2 to 10
The optical composite films as provided in example 1 have the technical parameters as shown in table 1.
The technical parameters of examples 1-10 are shown in tables 1-1 and 1-2 below.
Table 1-1 technical parameters of the first optical film of the optical composite films provided in examples 1-10
Figure BDA0002215077450000141
Note: the refractive index of the prism resin is generally the refractive index of the glue before curing, and the index that can be detected is also the refractive index before curing, so the index may be referred to as the refractive index of the liquid.
Tables 1-2 technical parameters of the second optical film and the adjacent layer of the optical composite films provided in examples 1-10
Figure BDA0002215077450000142
Figure BDA0002215077450000151
Comparative example 1
As shown in fig. 1, the conventional diffusion prism composite film has a structure including a first substrate layer 10, a glue layer 11, a diffusion particle layer 12, a bonding layer 13, a second substrate layer 20, a prism layer 21, and a back coating layer 22.
The technical parameters of the diffusion film, the adhesive layer 13, the second substrate layer 20, the prism layer 21 and the back coating layer 22 are the same as those of the example 1 by coating the glue and the particles on the PET film surface according to the conventional method by using a coating mode. The common diffusion prism composite film can be prepared. The technical parameters of the first optical film are shown in table 2 below.
Table 2 technical parameters in the diffusion membrane provided in comparative example 1
Figure BDA0002215077450000152
Figure BDA0002215077450000161
Note: the exposed degree of the particles is the height of the particles exposed outside the glue layer.
Comparative example 2
As shown in fig. 2, the conventional regular microlens prism composite film includes a first substrate layer 30, a microlens structure layer 31, a laminating layer 32, a second substrate layer 40, a prism layer 41, and a back coating layer 42.
The technical parameters of the regular microlens structure, the adhesive layer 32, the second substrate layer 40, the prism layer 41 and the back coating layer 42 are the same as those of example 1 by using a metal mold according to a conventional method. The regular microlens prism composite film can be prepared. The technical parameters are shown in table 3 below.
Table 3 technical parameters of the microlens provided in comparative example 2
Figure BDA0002215077450000162
The main properties of the optical composite films provided in examples and comparative examples are shown in table 4. The cost of the optical composite films provided in examples and comparative examples is shown in table 5.
TABLE 4 measurement results of main properties of optical composite films provided in examples 1 to 10 of the present invention and comparative examples 1 to 2
Figure BDA0002215077450000163
Figure BDA0002215077450000171
TABLE 5 comparison of cost results of optical composite films provided in examples 1 to 10 of the present invention and comparative examples 1 to 2
Content providing method and apparatus Cost of
Example 4 100％
Example 8 100％
Example 9 100％
Example 10 96％
Comparative example 1 115％
Comparative example 2 100％
The results of the tests shown in table 4 show that the optical composite film provided by the present invention has the characteristics of high brightness, high covering power and reduced light interference. In particular, the combination of the properties of examples 8-10 of the present invention is superior.
The above description is only a preferred embodiment of the present invention, and is not intended to limit the scope of the present invention. All equivalent changes and modifications made according to the disclosure of the present invention are covered by the scope of the claims of the present invention.

Claims (10)

1. An optical composite film, comprising: a first layer of optical film and a second layer of optical film; the first layer of optical film is arranged above the second layer of optical film, and the first layer of optical film and the second layer of optical film are bonded together through the laminating layer; the first optical film layer sequentially comprises a micro-lens structure layer and a first substrate layer from top to bottom; the second layer of optical film sequentially comprises a prism layer, a second base material layer and a back coating layer from top to bottom.
2. The optical composite film of claim 1 wherein the microlens structure layer comprises a microlens structure and a glue layer, the microlens structure is bonded to the upper surface of the first substrate layer through the glue layer, and the microlens structure and the glue layer are made of the same material.
3. An optical composite film according to claim 1 wherein the microlens structure and the glue layer are integrally formed during the fabrication process.
4. The optical composite film of claim 2 wherein the microlens structures of the first optical film are arcuate projections.
5. An optical composite film according to claim 4 wherein the arcuate projections have a width of 10 to 100 μm and an aspect ratio of 0.6 to 1.4.
6. An optical composite film as recited in claim 5, wherein the duty cycle of the arcuate projections is from 85% to 95%.
7. The optical composite film according to claim 4, wherein in the first optical film, the microlenses in the microlens structure layer are hemispherical, the width of the hemispherical microlenses is 10-100 μm, the aspect ratio is 0.3-0.6, the duty ratio is 60-95%, the refractive index of the liquid resin used for the microlenses is 1.44-1.60, the material of the first substrate layer is selected from one of polyethylene terephthalate (PET), Polycarbonate (PC), polyvinyl chloride (PVC) or polymethyl methacrylate (PMMA), and the thickness of the first substrate layer is 38-250 μm; in the second layer of optical film, the distance between the strip-shaped prism structures of the prism layer is 20-90 μm, the refractive index of the resin adopted by the prism structures is 1.53-1.58, the material of the second layer of substrate layer is selected from one of polyethylene terephthalate (PET), Polycarbonate (PC), polyvinyl chloride (PVC) or polymethyl methacrylate (PMMA), and the thickness of the second layer of substrate layer is 38-250 μm; the thickness of the attaching layer is 0.5-5 μm.
8. The optical composite film according to claim 7, wherein in the first optical film, the microlenses in the microlens structure layer are hemispherical, the width (diameter) of the hemispherical microlenses is 20-60 μm, the aspect ratio is 0.35-0.55, the duty ratio is 70-95%, the refractive index of the liquid resin used for the microlenses is 1.46-1.56, the material of the first substrate layer is selected from polyethylene terephthalate (PET) or Polycarbonate (PC), and the thickness of the first substrate layer is 100-188 μm; in the second layer optical film, the distance between the strip-shaped prism structures of the prism layer is 30-80 μm, the refractive index of the resin adopted by the prism structures is 1.54-1.57, the material of the second layer substrate layer is selected from polyethylene terephthalate (PET) or Polycarbonate (PC), and the thickness of the second layer substrate layer is 100-188 μm; the thickness of the attaching layer is 0.5-2 μm.
9. The optical composite film according to claim 8, wherein in the first optical film, the microlenses in the microlens structure layer are hemispherical, the width (diameter) of the hemispherical microlenses is 25-45 μm, the aspect ratio is 0.4-0.5, the duty ratio is 85-95%, the refractive index of the liquid resin used for the microlenses is 1.48-1.52, the material of the first substrate layer is selected from polyethylene terephthalate (PET), and the thickness of the first substrate layer is 125 μm; in the second layer optical film, the distance between the strip-shaped prism structures of the prism layer is 60-70 μm, the refractive index of resin adopted by the prism structures is 1.55-1.56, the material of the second layer substrate layer is selected from polyethylene terephthalate (PET), and the thickness of the second layer substrate layer is 125 μm; the thickness of the attaching layer is 0.5-1.2 μm.
10. A method of making an optical composite film according to any one of claims 1-9 comprising the steps of:
1. preparation of the first layer optical film
(1) Preparing a microstructure substrate: distributing a layer of micro-particles on the surface of a substrate by an autodeposition method, and then depositing glue in the gaps among the particles in a deposition mode;
(2) removing the microstructure particles, and preparing a master plate: coating polymer resin on the microparticle layer on the upper surface of the substrate prepared with the glue deposition layer and the microparticle layer, and curing the polymer resin to form close adhesion with the microparticles; peeling the uppermost layer of polymer resin and the microparticles from the substrate, and leaving the substrate and the glue deposition layer, wherein the upper surface of the glue deposition layer forms a concave microstructure arrangement layer, and the part is the prepared mother film;
(3) preparation of microlens film: the mother film is coated on the outer wall of the production line roller, the seam is bonded through an adhesive tape, glue is coated on the surface of the first layer of the base material layer, a glue layer is pressed on the surface of the mother film with the concave microstructures, the glue is solidified, and the convex microstructure lens layer can be formed on the first optical surface of the first layer of the base material layer, so that the first layer of the optical film can be obtained.
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Application publication date: 20200724